CN112388147A

CN112388147A - Method and vessel for loading feedstock rods into an additive friction stir deposition machine

Info

Publication number: CN112388147A
Application number: CN202010806557.XA
Authority: CN
Inventors: 罗盖·I·罗德里格斯; 布鲁诺·萨莫拉诺·森德罗斯
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2019-08-13
Filing date: 2020-08-12
Publication date: 2021-02-23
Anticipated expiration: 2040-08-12
Also published as: GB2587701A; GB202010397D0; US20210046579A1; GB202010537D0; GB2587701B; CN112388147B; US11370058B2

Abstract

The present disclosure describes a method and container for loading feedstock rods into an additive friction stir deposition machine (AFSD). The method includes housing a plurality of feedstock rods in a vessel disposed adjacent to a mandrel of an additive friction stir deposition machine. The method also includes moving one of the plurality of feedstock rods into axial alignment with a mandrel of the additive friction stir deposition machine.

Description

Method and vessel for loading feedstock rods into an additive friction stir deposition machine

Technical Field

The present invention relates to additive manufacturing, and more particularly, to an Additive Friction Stir Deposition (AFSD) machine.

Background

In additive manufacturing, material is typically deposited layer by layer to form a three-dimensional part. Additive manufacturing is popular because it enables the use of a variety of materials, including ceramics, glass, thermoplastics, and metal powders, to form parts with complex geometries.

Additive manufacturing includes different techniques for depositing materials in different ways. For example, directed energy deposition and material extrusion additive manufacturing involve deposition of molten material. Other techniques sinter the powder material to build up a layer, such as certain types of powder bed melting. However other additive manufacturing techniques are solid state. One such technique is known as Additive Friction Stir Deposition (AFSD). In AFSD, an additive material is deposited on a substrate or preformed layer by friction forces that stir and deform the material without heating the material to its melting point. Thus, AFSD is capable of producing parts with desired material properties at low heat levels without the need for sintering and other post-processing. AFSD can also support the formation of widely scalable component sizes and geometries, repair and coating processes, as well as the manufacture, use of multiple materials, and operation in open air environments.

In some implementations of an AFSD, a mandrel receives the additive material and rotates to apply frictional forces to the material at the material/substrate interface to stir, soften, and deposit the material. In some examples, the additive material is in the form of solid, discrete feedstock rods that are fed seriatim into the mandrel. However, loading the mandrels in this manner presents various challenges that adversely affect the manufacturing process of the AFSD. For example, when loading another feedstock bar, the mandrel must be stopped from rotating prior to reloading. As a result, the component formation is interrupted. Furthermore, in some instances, the mandrel must also be moved to an intermediate position to reload the feedstock, and then moved back into position relative to the part before deposition resumes. These process interruptions reduce the overall average deposition rate and require operator intervention to reload the feedstock.

Another consequence of such interruptions is that the deposited feedstock may experience a cool down period during the interruption, which may reduce the quality of the part formed from such feedstock and limit potential part geometry. Furthermore, in some instances where feedstock rods are loaded one by one, the deposition process must be stopped before the entire feedstock rod is utilized. In these examples, the end portion of each raw material rod fed into the mandrel is not deposited, thereby generating waste. Therefore, in view of the above, there are challenges in the AFSD manufacturing process using raw material rods, such as increasing the deposition rate and improving the quality of the deposited material.

Disclosure of Invention

To address the above issues, according to one aspect of the present disclosure, a method for loading feedstock rods into an Additive Friction Stir Deposition (AFSD) machine is provided. In this aspect, the method includes housing a plurality of feedstock rods in a vessel disposed adjacent to a mandrel of an additive friction stir deposition machine. The method also includes moving one of the plurality of feedstock rods into axial alignment with a mandrel of the additive friction stir deposition machine.

Another aspect of the present disclosure relates to a container for loading a feedstock bar into an additive friction stir deposition machine. In this aspect, the vessel includes a staging mechanism configured to move one of the plurality of feedstock rods held within the vessel into axial alignment with a mandrel of the additive friction stir deposition machine.

Another aspect of the present disclosure relates to a system for loading a feedstock bar into an additive friction stir deposition machine. In this aspect, the system includes a container configured to hold a plurality of feedstock rods. In this aspect, the system further includes a preparation mechanism configured to move one of the plurality of feedstock rods into axial alignment with a mandrel of the additive friction stir deposition machine. In this aspect, the system further includes a loading actuator configured to insert one feedstock rod into a mandrel of the additive friction stir deposition machine.

The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which will be apparent with reference to the following description and drawings.

Drawings

Fig. 1A-1C show diagrams depicting portions of an Additive Friction Stir Deposition (AFSD) system and an AFSD machine according to example embodiments of the present disclosure.

FIG. 2 shows a plan sectional view schematically depicting a vessel of the AFSD system of FIGS. 1A-1C, according to an example embodiment of the present disclosure.

FIG. 3 illustrates a cut-away view of the AFSD system of FIGS. 1A-1C including a preparation actuator, according to an example embodiment of the present disclosure.

FIG. 4 shows a cross-sectional view of the AFSD system of FIGS. 1A-1C including a preparation spring, according to an example embodiment of the present disclosure.

FIG. 5 shows a cross-sectional view of the AFSD system of FIGS. 1A-1C including a rotating lever, according to an example embodiment of the present disclosure.

FIG. 6 shows a plan cross-sectional view of a vessel of the AFSD system of FIGS. 1A-1C including another rotating lever, according to an example embodiment of the present disclosure.

FIG. 7 shows a plan cross-sectional view of the vessel of the AFSD system of FIGS. 1A-1C including a chain, according to an example embodiment of the present disclosure.

FIG. 8 shows a cut-away view of the AFSD system of FIGS. 1A-1C including the vessel and chain of FIG. 7, according to an example embodiment of the present disclosure.

FIG. 9 shows a diagrammatic view of the vessel of the AFSD system of FIGS. 1A-1C including a rotating gear.

FIG. 10 shows a flow chart illustrating a method of loading feedstock sticks into an AFSD machine.

Detailed Description

In view of the considerations discussed above, systems, methods, and apparatus related to loading feedstock rods for deposition in Additive Friction Stir Deposition (AFSD) manufacturing are provided. Briefly, a plurality of feedstock rods are held in a container of an AFSD machine, with one of the feedstock rods being moved from a staging position into axial alignment with a spindle of the AFSD machine by a staging mechanism. Multiple feedstock bars are held in the container by various structures and/or mechanisms, such as coil springs, chains, and gear assemblies. The priming mechanism may take different forms, including an actuator (e.g., a motor), a priming spring, and a lever.

The use of a container to hold and prepare a plurality of feedstock rods enables individual rods to be fed into a mandrel and deposited substantially continuously. As such, such a vessel enables operation of an AFSD machine with an increased average deposition rate and with reduced or no operator involvement. The example implementations described herein also allow for the preparation and loading of feedstock bars without stopping the rotation of the mandrel. Substantially continuous deposition of feedstock also reduces the cool-down period that occurs due to interrupted deposition, resulting in higher part quality and more complex geometries. Furthermore, each raw material rod can be completely deposited, thereby reducing waste. As a result, the yield of parts can be higher and the cost reduced.

FIGS. 1A-1C illustrate an example AFSD system 100 that includes portions of an AFSD machine 102. AFSD system 100 includes a container 104 disposed adjacent a mandrel 108 of AFSD machine 102. The container 104 is configured to hold a plurality of feedstock rods 106. Each feedstock bar 106 is keyed in cross-section for receipt in a correspondingly shaped bore 115 extending through the mandrel 108. As such, referring to fig. 1B, individual feedstock rods 106A are fed downward through a rotating mandrel 108 to create frictional heating at the interface of the rotating feedstock rods 106A and the previously formed layer 114 (in the example of fig. 1B) or base substrate 118. This frictional heating and rotation of feedstock bar 106A causes feedstock bar 106A to agitate and deform as substrate 118 and rotating mandrel 108 move relative to each other, thereby creating softened material that is deposited to form new layer 112 on top of previously formed layer 114 of features 116 formed on substrate 118.

In the example of fig. 1A-1C, feedstock bar 106 has a square cross-section. In other example implementations, the feedstock bar may take on a rectangular, triangular, or other suitable cross-section. Further, the mandrel 108 and container 104 are rotated in synchronism, as indicated at 109, to enable successive loading of multiple feedstock bars 106 without stopping the mandrel from rotating, as described in more detail below. In various implementations, the container 104 is fixedly or removably coupled to the mandrel 108 to facilitate such synchronized rotation. In some examples, the loading actuator 110 may also rotate with the container 104 and the mandrel 108.

Referring to fig. 1A and 1B, and as described in greater detail below, to load feedstock rods 106 into a mandrel 108, a particular feedstock rod 106A is placed in axial alignment with a mandrel 108 disposed adjacent to a vessel 104. With feedstock bar 106A axially aligned with mandrel 108, loading actuator 110 of AFSD machine 102 pushes feedstock bar 106A through lower aperture 128 of container 104 into aperture 115 of mandrel 108, as shown in FIG. 1B. The loading actuator 110 may include an electric motor, hydraulic cylinder, pneumatic actuator, or other component for moving the loading shaft 111 to contact the feedstock bar 106A.

During deposition of feedstock rod 106A, loading shaft 111 is retracted and the next feedstock rod 106B is moved from ready position 120 (not axially aligned with mandrel 108) into axial alignment with mandrel 108. Referring now to fig. 1C, the next feedstock bar 106B is then fed into the mandrel 108 by the loading actuator 110, abutting the feedstock bar 106A. In some implementations, movement of feedstock bar 106B from ready position 120 into axial alignment with mandrel 108 results from rotating the plurality of feedstock bars 106 within container 104 to advance feedstock bar 106B into such axial alignment. This process, repeated rotation of feedstock rods 106, movement of individual feedstock rods 106 from ready position 120 into axial alignment with mandrel 108, and loading of individual feedstock rods 106 into mandrel 108, may be repeated such that each feedstock rod 106 held in container 104 is deposited into one or more layers on substrate 118. Accordingly, a plurality of feedstock rods 106 may be deposited in a substantially continuous manner without stopping the rotation of the mandrel 108, thereby achieving the advantages associated with the above-described deposition.

The AFSD machine 102 can employ various mechanisms to receive a plurality of feedstock rods 106 in the container 104, position each feedstock rod 106 in a ready position, and move each feedstock rod 106 from the ready position into axial alignment with the mandrel 108. Examples of such mechanisms are described below; briefly, FIG. 2 illustrates a coil spring for biasing feedstock bar 106, FIG. 3 illustrates the use of an actuator to align feedstock bar 106 with mandrel 108, FIG. 4 illustrates the use of a ready spring to align feedstock bar 106 with mandrel 108, FIGS. 5 and 6 illustrate the use of a lever to align feedstock bar 106 with mandrel 108, FIGS. 7 and 8 illustrate the use of a chain and motor to receive and align feedstock bar 106 with mandrel 108, and FIG. 9 illustrates the use of a gear-based wheel to receive and align feedstock bar 106 with mandrel 108.

In some examples, reloading the container 104 with feedstock bars 106 includes holding the container 104 in a fixed position relative to the mandrel 108 (i.e., the position shown in fig. 1A-1C), and loading new feedstock bars 106 into the container 104 through a door 122 on the container 104. As shown in fig. 1A-1C, the door 122 is disposed on a side surface 124 of the container 104. In other examples, the loading door is disposed on a top or bottom surface of the container 104.

In other examples, the feedstock bar 106 is loaded into the vessel 104 through an upper aperture 126 exposed by removing the loading shaft 111 from the vessel 104, and/or a lower aperture 128 exposed by decoupling the mandrel 108 from the vessel 104. Here, after loading the feedstock bars 106, the preparation and/or loading mechanism (examples of which will be described below) is retracted or biased such that the feedstock bars 106 are placed in a preloaded arrangement with one of the feedstock bars 106 disposed in the preparation position 120.

In instances where the position of the container 104 relative to the mandrel 108 and the loading actuator 110 remains unchanged, the alignment of the container 104 with the mandrel 108 also remains unchanged. In other examples, container 104 can be removed from AFSD machine 102 for purposes such as facilitating reloading container 104 with feedstock bars 106, performing maintenance on container 104, or other purposes. In these examples, alignment mechanism 130 can be employed to align container 104 with mandrel 108 when container 104 is reinserted into AFSD machine 102. The alignment mechanism 130 may take the form of a frame, a bracket, a tool, or any other suitable form to align the container 104 with the mandrel 108. In some examples, feedstock rods 106 can be loaded into additional containers 104 and inserted into AFSD machine 102 to replace empty containers 104, thereby further reducing downtime and increasing deposition throughput.

As one example, component 116 manufactured using AFSD machine 102 can be a preform. In other examples, AFSD machine 102 is used to form any suitable type of component, including but not limited to aircraft and vehicle components. In addition to forming new components, AFSD machine 102 can also be used to repair and/or coat existing components. Further, as described above, AFSD machine 102 can utilize feedstock rods 106 of any suitable type and size. By way of example, feedstock bar 106 may be configured to have a length of 1 to 2 feet.

As described above, the container 104 may include a variety of different mechanisms to retain and position the feedstock bar 106 therein. Fig. 2 illustrates a plan cross-sectional view of the container 104 in an example in which a coil spring 200 is used to position a plurality of feedstock bars 106. In this example, the coil spring 200 is compressed and, when released, applies a biasing force to the feedstock bar 106 by contacting the lever 204 of the rearmost feedstock bar 106B. This force is transferred to the other feedstock bars 106 by the mechanism coupling the feedstock bars 106 together or by direct contact between adjacent feedstock bars with each other such that the forward-most feedstock bar 106A is biased to the ready position 120. Thus, the coil spring 200 functions to position the feedstock bar 106A in the ready position 120 for subsequent axial alignment with the lower bore 128 and insertion into the mandrel 108. An example mechanism for moving the feedstock bar 106A into axial alignment with the lower bore 128 is described below with reference to fig. 3-6.

In one implementation, the container 104 includes a track 206 to guide movement of the feedstock bars 106 from a relatively more radially outward position, in which the feedstock bars 106 are shown in fig. 2, toward the ready position 120. While fig. 2 depicts a particular length and geometry of the track 206, it should be understood that these properties are variable — for example, the track 206 may be configured to have a relatively long length that winds or spirals toward the ready position 120, which enables a greater number of feedstock rods 106 to be retained within the container 104. Thus, the coil spring 200 is properly positioned in the container 104, including above and below the feedstock bar 106, in view of the configuration of the track 206. In the example shown in fig. 2, the coil spring 200 is disposed adjacent the lower aperture 128 and extends along at least a portion of the axial length of the container 104. Further, the coil spring 200 may be compressed again at any suitable time, such as when the container 104 is reloaded with feedstock rods 106.

As described above, the container 104 includes a ready mechanism to move the feedstock bar 106 from the ready position 120 into axial alignment with the lower bore 128, and thus the mandrel 108 and its bore 115. FIG. 3 illustrates a cross-sectional view of AFSD system 100 in one example, wherein first preparatory actuator 300A and second preparatory actuator 300B are used to move feedstock bar 106A from preparatory position 120 into axial alignment with mandrel 108. Fig. 3 particularly depicts a state in which the feedstock bar 106A is disposed in the ready position 120, the mandrel 108 is empty, and the loading shaft 111 is fully retracted from the container 104. In this state, the preparation actuator 300 contacts and applies a lateral force to move the feedstock bar 106A into axial alignment with the mandrel 108. Preparation actuator 300 may take any suitable form including, but not limited to, an electric motor, a hydraulic cylinder, a pneumatic actuator, or other components.

As another example of a priming mechanism, FIG. 4 illustrates a cross-sectional view of AFSD system 100 in one example, wherein priming spring 400 is used to move feedstock bar 106A from priming position 120 into axial alignment with mandrel 108. The ready spring 400 is compressed and then released, moving the feedstock bar 106A from the ready position 120 into axial alignment with the mandrel 108. In some examples, spring 400 is compressed when container 104 is loaded with feedstock bar 106 (e.g., where such loading is performed after container 104 is removed from AFSD machine 102). In other words, the feedstock bar 106, when loaded into the container 104, provides a compressive force to the spring 400, thereby placing the spring 400 in a compressed state. In other examples, a side door on the container 104, such as door 122, may be used to load the feedstock bar 106, thereby compressing the spring 400. In yet another example, a removable linear magazine (magazine) loaded into the container 104 from the outside may be used to load the feedstock sticks 106 and compress the spring 400.

As another example of a priming mechanism, FIG. 5 illustrates a cross-sectional view of AFSD system 100 in one example, wherein rotary rod 500 is used to move feedstock bar 106A from priming position 120 into axial alignment with mandrel 108. The rotary rod 500 may rotate about a rotational axis 502, which may be substantially perpendicular to the longitudinal axis of the feedstock bar 106A. In the depicted example, rotation of the rotary rod 500 in a clockwise direction applies a force that moves the feedstock bar 106A into axial alignment with the mandrel 108. The rod 500 is then rotated counterclockwise until the next feedstock bar 106 is placed in the ready position 120. Any suitable actuator may be used to drive the rotary rod 500, including but not limited to the example actuators discussed above.

The container 104 may employ other types of rotating mechanisms to move the feedstock bar 106A from the ready position 120 into axial alignment with the mandrel 108. As another example, fig. 6 illustrates a plan cross-sectional view of a container 104 in one example, where a rotary rod 600 is used in conjunction with a preparation actuator 602 to prepare and align a feedstock bar 106A. The rotary rod 600 is rotated about an axis substantially parallel to the longitudinal axis of the feedstock bar 106A (shown in the ready position 120), thereby moving the feedstock bar 106A into axial alignment with the lower bore 128 and the mandrel 108. In one example, the rod 600 is located at about the middle along the longitudinal axis of the container 104. In other implementations, two or more rods 600 are positioned at spaced apart locations along the longitudinal axis of the vessel 104 to contact the feedstock bar 106A at different locations along the feedstock bar.

In the event that the ready position 120 is not occupied by a feedstock bar 106A, the ready actuator 602 advances the next feedstock bar 106B from the intermediate position 604 to the ready position 120. Any suitable actuator may be used to drive the rotating rod 600, including, but not limited to, the example actuators described above for the preparation actuator 602.

As another example of a mechanism for holding and preparing the raw material rods 106, fig. 7 illustrates a plan sectional view of the container 104 in an example in which a plurality of raw material rods 106 are connected to each other by a chain 700. An actuator 702 (see fig. 8) is coupled to the chain 700 and configured to drive the chain 700 and move each feedstock bar 106 through the interconnection of the feedstock bars 106 with the chain 700. In operation, the feedstock bar 106A is moved from the ready position 120 into axial alignment with the lower bore 128 and the mandrel 108.

While fig. 7 depicts a particular length and geometry of the chain 700, it should be understood that these properties are variable — for example, the chain 700 may be configured to have a relatively long length that winds or spirals toward the ready position 120, which enables a greater number of feedstock rods 106 to be retained within the container 104. As an example, the chain 700 may be arranged in a circular or elliptical path.

FIG. 8 illustrates a cross-sectional view of AFSD system 100, wherein container 104 is configured to position feedstock bars 106 using chain 700. In the depicted state, the raw material bar 106A is disposed at the ready position 120. As the feedstock bar 106A is advanced into axial alignment with the mandrel 108 by the actuator 702, the loading actuator 110 applies force to load the feedstock bar 106A into the mandrel 108 for deposition, as described above. The actuator 702 may take any suitable form, including but not limited to a stepper motor. In such an example, the stepper motor advances the feedstock bar 106 to a position previously occupied by another feedstock bar 106. For example, in operation, the stepper motor advances the feedstock bar 106A from the ready position 120 into axial alignment with the mandrel 108.

Although the location of the chain 700 is depicted in this example as being toward the bottom of the container 104, in other examples the chain 700 is disposed in other locations, such as near the middle or middle of the container 104 (along the longitudinal axis) or at the top of the container. Further, chain 700 may be configured in any suitable manner. In some examples, the chain 700 is consumable, in which case the chain 700 can be removed and replaced (e.g., when reloading the feedstock bar 106 into the container 104).

As another example of a mechanism for holding and preparing the raw material bar 106, fig. 9 illustrates a partial view of the container 104 provided with a preparation mechanism having a first gear 900A and a second gear 900B. Each feedstock bar 106 is removably retained within a gap 902 formed between adjacent teeth of each gear. The feedstock bar 106A is removably retained within the gap 902A of the gear 900A and is advanced from the ready position into axial alignment with the mandrel 108 by rotational movement of the gear 900A. With the feedstock bar 106A axially aligned with the mandrel 108, the loading actuator 110 and loading shaft 111 apply a force to the feedstock bar 106A to move the feedstock bar 106A into the mandrel 108 for deposition, as described above.

In the depicted example, gears 900A and 900B each counter rotate to advance feedstock bar 106, although any suitable type of gear motion may be used. In other examples, the container 104 utilizes other numbers of gears 900, including a single gear 900. Any suitable actuator or actuators may be used to actuate

gears

900A and 900B, including but not limited to a stepper motor provided for each

gear

900A and 900B, respectively.

FIG. 10 illustrates a flow chart illustrating a method 1000 for loading feedstock bars into an AFSD machine. For example, method 1000 can be performed to load feedstock bars 106 into AFSD machine 102.

At 1002, method 1000 includes receiving a plurality of feedstock rods (e.g., feedstock rods 106) in a container (e.g., container 104) disposed adjacent a mandrel (e.g., mandrel 108) of an AFSD machine. In some examples, a plurality of feedstock bars are connected 1004 to one another by a chain (e.g., chain 700). In some examples, the container includes a coil spring (e.g., coil spring 200), and the plurality of feedstock rods are biased 1006 in the container by the coil spring.

At 1008, method 1000 includes moving one of the plurality of feedstock rods (e.g., feedstock rod 106A) into axial alignment with a mandrel of the AFSD machine. In some examples, moving one feedstock bar into axial alignment with the mandrel includes contacting 1010 the one feedstock bar with at least one preparation actuator (e.g., preparation actuator 300). In some examples, moving the one feedstock bar into axial alignment with the mandrel includes actuating 1012 at least one spring (e.g., priming spring 400) to move the one feedstock bar. In some examples, moving the one feedstock bar into axial alignment with the mandrel includes contacting 1014 the one feedstock bar with at least one rotary rod (e.g., rotary rod 500, rotary rod 600). Where a chain connects multiple feedstock bars, in some examples, moving the one feedstock bar into axial alignment with the mandrel includes driving 1016 the multiple feedstock bars via a motor (e.g., actuator 702) coupled to the chain. In some examples, moving the one feedstock bar into axial alignment with the mandrel comprises rotating 1018 multiple feedstock bars. At 1020, method 1000 includes inserting the one feedstock rod into a mandrel of an AFSD machine.

Further, the present disclosure includes examples according to the following clauses:

clause 1. a method for loading a feedstock bar into an additive friction stir deposition machine, the method comprising: receiving a plurality of feedstock rods in a vessel disposed adjacent to a mandrel of an additive friction stir deposition machine; and moving one of the plurality of feedstock rods into axial alignment with a mandrel of the additive friction stir deposition machine.

Clause 2. the method of clause 1, further comprising inserting the one feedstock bar into a mandrel of an additive friction stir deposition machine.

Clause 3. the method of clause 1, wherein moving the one feedstock bar into axial alignment with the mandrel comprises contacting the one feedstock bar with at least one preparation actuator.

Clause 4. the method of clause 1, wherein moving the one feedstock bar into axial alignment with the mandrel comprises actuating at least one spring to move the one feedstock bar.

Clause 5. the method of clause 1, wherein moving the one feedstock bar into axial alignment with the mandrel comprises contacting the one feedstock bar with at least one rotating rod.

Clause 6. the method of clause 1, wherein the plurality of feedstock rods in the vessel are connected to each other by a chain.

Clause 7. the method of clause 6, wherein moving the one feedstock bar into axial alignment with the mandrel comprises driving a plurality of feedstock bars by a motor coupled to a chain.

Clause 8. the method of clause 1, wherein the container includes a coil spring, the method further comprising biasing the plurality of feedstock rods in the container with the coil spring.

Clause 9. the method of clause 1, wherein moving the one feedstock bar into axial alignment with the mandrel comprises rotating a plurality of feedstock bars.

Clause 10. a container for loading a feedstock bar into an additive friction stir deposition machine, the container comprising: a preparation mechanism configured to move one of the plurality of feedstock rods held within the vessel into axial alignment with a mandrel of the additive friction stir deposition machine.

Clause 11. the container of clause 10, wherein the preparation mechanism includes at least one preparation actuator.

Clause 12. the container of clause 11, wherein the one feedstock bar is biased into the ready position by a coil spring, and the at least one ready actuator is configured to move the one feedstock bar from the ready position in the container into axial alignment with the mandrel.

Clause 13. the container of clause 10, wherein the plurality of feedstock rods are connected to each other by a chain, and wherein the preparation mechanism is configured to drive the chain and move the one feedstock rod into axial alignment with the mandrel.

Clause 14. the container of clause 10, wherein the preparation mechanism comprises a motor.

Clause 15. the container of clause 10, wherein the preparation mechanism comprises a rotating lever.

Clause 16. the container of clause 10, wherein the preparation mechanism includes at least one spring.

Clause 17. the container of clause 10, wherein the preparation mechanism includes at least one gear that removably holds the plurality of feedstock rods and moves the one feedstock rod into axial alignment with the mandrel.

Clause 18. a system for loading a feedstock bar into an additive friction stir deposition machine, the system comprising: a container configured to hold a plurality of feedstock rods; a preparation mechanism configured to move one of a plurality of feedstock rods into axial alignment with a mandrel of an additive friction stir deposition machine; and a loading actuator configured to insert the one feedstock rod into a mandrel of an additive friction stir deposition machine.

Clause 19. the system of clause 18, wherein the priming mechanism comprises one of a priming actuator, a priming spring, a rotating lever, and a gear.

Clause 20. the system of clause 18, wherein the preparation mechanism includes a pair of preparation actuators that contact the one feedstock bar and move the one feedstock bar into alignment with the mandrel.

The apparatus, systems, and methods described herein have the potential benefits of increasing the deposition rate and throughput of an AFSD machine, reducing operator involvement, reducing material waste, increasing part throughput and economy, increasing part quality, and increasing possible part geometry.

The present disclosure includes all novel and nonobvious combinations and subcombinations of the various features and techniques disclosed herein. The various features and techniques disclosed herein are not required for all examples of the disclosure. Furthermore, various features and techniques disclosed herein may define patentable subject matter other than the disclosed examples, and may be used in other implementations not explicitly disclosed herein.

Claims

1. A method (1000) for loading a feedstock bar (106) into an additive friction stir deposition machine (102), the method (1000) comprising:

receiving (1002) a plurality of feedstock rods (106) in a vessel (104) disposed adjacent a mandrel (108) of the additive friction stir deposition machine (102); and

moving (1008) one feedstock bar (106A) of the plurality of feedstock bars (106) into axial alignment with the mandrel (108) of the additive friction stir deposition machine (102).

2. The method (1000) of claim 1, further comprising inserting (1020) the one feedstock bar (106A) into the mandrel (108) of the additive friction stir deposition machine (102).

3. The method (1000) of claim 1, wherein moving (1008) the one feedstock bar (106A) into axial alignment with the mandrel (108) includes contacting (1010) the one feedstock bar (106A) with at least one preparation actuator (300A).

4. The method (1000) of claim 1, wherein moving (1008) the one feedstock bar (106A) into axial alignment with the mandrel (108) comprises actuating (1012) at least one spring (400) to move the one feedstock bar (106A).

5. The method (1000) of claim 1, wherein moving (1008) the one feedstock bar (106A) into axial alignment with the mandrel (108) comprises contacting (1014) the one feedstock bar (106A) with at least one rotating rod (500).

6. The method (1000) of claim 1, wherein the plurality of feedstock bars (106) in the vessel (104) are connected to one another via a chain (700), and wherein moving (1008) the one feedstock bar (106A) into axial alignment with the mandrel (108) comprises driving (1016) the plurality of feedstock bars (106) via a motor (702) coupled to the chain (700).

7. The method (1000) of claim 1, wherein the vessel (104) includes a coil spring (200), the method (1000) further comprising biasing (1006) the plurality of feedstock bars (106) in the vessel (104) via the coil spring (200).

8. The method (1000) of claim 1, wherein moving (1008) the one feedstock bar (106A) into axial alignment with the mandrel (108) comprises rotating (1018) the plurality of feedstock bars (106).

9. A container (104) for loading feedstock rods (106) into an additive friction stir deposition machine (102), the container (104) comprising:

a preparation mechanism (300) configured to move one feedstock bar (106A) of a plurality of feedstock bars (106) held in the vessel (104) into axial alignment with a mandrel (108) of the additive friction stir deposition machine (102).

10. The container (104) of claim 9, wherein the one feedstock bar (106A) is biased to a ready position (120) by a coil spring (200), and at least one ready actuator (300A) is configured to move the one feedstock bar (106A) from the ready position (120) in the container (104) into axial alignment with the mandrel (108).

11. The container (104) of claim 9, wherein the plurality of feedstock bars (106) are connected to each other by a chain (700), and wherein the preparation mechanism (300) is configured to drive the chain (700) and move the one feedstock bar (106A) into axial alignment with the mandrel (108).

12. The container (104) of claim 9, wherein the preparation mechanism (300) includes at least one gear (900A) that removably holds the plurality of feedstock bars (106) and moves the one feedstock bar (106A) into axial alignment with the mandrel (108).